How Stairlock Improved Productivity with Leitz Katana Sawblades

Based in Adelaide, South Australia, Stairlock designs and manufactures premium staircases for residential and multi-residential projects across the country. What began as a door manufacturing business evolved into a specialist staircase manufacturer in 1992, when the company introduced a unique locking stair system from the United States

Today, Stairlock remains the only Australian manufacturer producing staircases using this proprietary system.

With approximately 60 employees across Australia and warehouse facilities in Victoria and New South Wales, Stairlock has grown into one of Australia’s leading staircase manufacturers.

Their Adelaide production facility is a hive of activity, capable of producing up to 45 staircases per day, with some production stations operating on cycle times as short as ten minutes.

At the heart of the business are a set of values that drive every decision. Lachlan Grzywacz, Stairlock Production Manager, comments “Challenging the Status Quo is a big one for us. It encourages innovation and continuous improvement, something we aim to embody daily in the business.”

It’s this value that led Stairlock to Leitz

Challenging the Status Quo

When a Leitz Technical Sales Representative first visited Stairlock, the company was experiencing an ongoing issue with the noise from their sawblade applications.

Despite using quality machinery and maintaining their equipment carefully, excessive noise from the saws had become a persistent issue throughout the workshop. The sound was so significant that it reverberated beyond the production floor and into the office areas.

Stairlock wanted a solution that would improve operator comfort without comprising productivity or cut quality. Working closely with the Stairlock team, Leitz recommended the Katana Circular Sawblade.

Quieter Cutting, Better Results

Designed specifically for demanding CNC and panel processing applications, the Katana features an innovative body design and vibration-dampening technology that significantly reduces noise emissions while delivering exceptional cutting performance.

Utilising specialised sound measurement equipment, testing was conducted before and after the blade changeover.

The results were remarkable.

“Noise levels were reduced by approximately 15 decibels, representing around a 500% reduction in sound pressure,” says Lachlan.

Impressed by the results, Stairlock progressively converted all applicable machines to Leitz Katana sawblades.

The benefits didn’t stop there.

Lachlan also noticed a significant improvement in cut quality, reducing the amount of sanding and rework required after machining. At the same time, the blades were delivering approximately three times the edge life of their previous tooling solution.

With sawblade changeovers typically taking around 30 minutes, fewer blade changes translates directly to reduced downtime and increased production capacity

Leitz Katana at a Glance:

The Leitz Katana circular sawblade is engineered to deliver exceptional cut quality, longer tool life and significantly reduced noise levels in demanding panel processing and CNC applications.

The innovative blade body design and vibration-dampening technology minimise noise and machine vibration, creating a more comfortable working environment while improving machining performance.

With cleaner cuts, reduced rework and extended edge life, the Katana helps manufacturers increase productivity, reduce downtime and achieve consistently superior results across a wide range of materials.

Precision where it Matters

Leitz has also supported Stairlock with the implementation of Leitz HeliCut Monoblock tooling for the machining of staircase posts.

Previously, achieving the required finish and dimensional consistency often required up to 15 minutes of manual rework per post.

The HeliCut solution significantly improved machining accuracy, delivering a more consistent finish directly off the machine.For a business producing high volumes every day, those savings quickly add up

Learn more about Leitz CNC tooling here.

A Partnership Focused on Improvement

For Stairlock, the relationship with Leitz extends beyond tooling.

The company values the technical expertise, responsiveness and ongoing support provided by the Leitz South Australia team. Whether discussing process improvements, tooling performance or new manufacturing challenges, Stairlock knows they have a partner committed to helping them find better solutions.

As a company approaching 150 years of manufacturing expertise, Leitz continues to work alongside Australian manufacturers like Stairlock to solve challenges, improve productivity and deliver better outcomes through advanced tooling technology and local support.

“The reduction in noise alone was enough to impress us, but the improvements in cut quality and tool life make the decision easy.” Lachlan reflects, “Leitz takes the time to understand our processes and deliver solutions that continue to improve our operations.”

Discover Leitz tool servicing here.

Looking to Improve Productivity in Your Workshop?

Whether you're chasing quieter cutting, longer tool life or a better finish, Leitz works with manufacturers across Australia and New Zealand to deliver tooling solutions tailored to your production needs.

Talk to your local Leitz Technical Sales Representative today.

Contact Leitz at sales@leitz.com.au or call 1300 135 127.